Attachment 3.
Work Plan/Project Map
Proposal Objective:
The objective of the proposed work is to achieve water conservation, energy efficiency and greenhouse gas (GHG) emission reductions at the City of Stockton Regional Wastewater Control Facility (RWCF), and at the Campbell Soup Company, tomato processing facility in Stockton, California.
The UCD proposal implements the Water Energy Nexus (WEN) Assessment methods to identify the technical and economic potential to achieve water conservation and energy efficiency at municipal and industrial facilities. The UCD proposal identifies multiple projects at the RWCF and at the Campbell Stockton facility. Each project has site-specific objectives.
At the RWCF location the objectives are to identify and implement energy efficiency measures and to increase biomethane production. The objectives at the Campbell Stockton facility are to achieve water conservation, recycle waste heat, adopt pump and fan systems’ electric energy conservation improvements, adopt thermal energy steam system improvements, and to improve wastewater and organic solid residue management practices.
The UCD proposal includes one structural project to achieve water conservation at the Campbell Stockton facility. This project will capture and utilize waste heat from hot tomato water vapors, capture and deliver clean water to targeted unit operations. This water and energy conservation infrastructure will require heat exchangers, storage tanks, motors and pumps, pipes and valves. The proposal includes a budget to fund the design and installation of the hot water conservation project at the Campbell Stockton facility.
The UCD proposal includes non-structural solution projects at the RWCF and the Campbell Stockton facility. UCD Researchers will conduct pump system assessments at the RWCF to establish the water energy intensity (WEi) metric and estimate electric power savings. The WEN Assessment project at the Campbell Stockton facility will conduct system assessments to identify electric and thermal energy efficiency improvement opportunities and estimate the technical potential to co-digest organic residues at the RWCF bioenergy generation facility.
The water conservation project at Campbell Stockton will deliver electric and thermal energy savings, with equivalent GHG emission reductions. The implementation of structural and non-structural solution projects will generate waste heat to replace natural gas, increase operational pumping plant efficiencies (OPEs), reduce cooling tower electric use and demand, reduce groundwater pumping, reduce wastewater discharge, enhance biomethane production.
The water conservation project located at the Campbell Stockton facility has the potential to conserve 35 million gallons of hot water per year and achieve electric and thermal energy cost savings. Additional benefits will be accrued through reduced utility costs for electricity, natural gas, wastewater treatment and landfill disposal. The electricity savings occur from the adoption of resource efficiency measures (REMs) identified by the Pump Energy System Assessments (Pump ESAs) conducted at the RWCF and the Campbell Stockton facilities.
Natural gas savings occur from the adoption of REMs identified by the Steam Energy System Assessment (Steam ESA) conducted at the Campbell Stockton facility. The wastewater treatment discharge cost reduction results from improvements identified by the Wastewater Management System Assessment conducted at the Campbell Stockton facility. This assessment will also identify the technical and economic potential to co-digest Campbell Stockton organic residues at the RWCF bioenergy generation facility. Reducing cost of landfill disposal for Campbell and increasing biogas yield revenues at the RWCF.
The WEN Assessment Tool methodology can be used by institutional water and wastewater agencies and their industrial customers anywhere in the state.
The WEN Assessment Tool
The WEN Assessment Tool (WEN Tool) integrates a systems approach to account for the supply-side and the demand-side of the water-energy nexus. The WEN Tool is used to evaluate the fresh water and wastewater systems at industrial and municipal facilities.
The UCD WEN Assessment methodology requires operational data to estimate the operating efficiency of pumps, fans, boilers, turbines and other equipment dedicated to the WEN relationship. The WEN Tool is used to establish the Water Energy intensity (WEi) metric at the RWCF and at the Campbell Stockton tomato processing facility. The WEN Tool is used to establish the WEi base-line at each unit-operation (WEN Points), where energy assets (motors, pumps, fans, boilers) are used to process water and wastewater. The WEi metric is used to recognize and identify resource (water, energy, air) efficiency measures (REMs).
In addition to establishing the WEi metrics at both facilities, UCD Researchers will design the RWCF WEN Tool to model the technical potential to enhance Biomethane generation at the RWCF, and to model the technical and economic potential to improve the Campbell Stockton wastewater management system and the potential to co-digest residues at the RWCF. The WEi metric is a scientific value to measure and validate (M&V) the economic and environmental benefits from conserving groundwater, enhancing electric and thermal energy efficiency and increasing bioenergy generation.
1.Research and Implementation Methods:
UCD Researchers utilize the American Society of Mechanical Engineers (ASME) Industrial Energy System Assessment (ESAs) standards[1], to estimate the operational plant efficiency (OPE) of industrial steam, pump and fan systems. Researchers utilize the Department of Energy (DOE)[2] Steam, Pump and Fan System Assessment Tools (SSAT, PSAT, and FSAT) to calculate the OPE of the equipment engaged in the WEN relationship. UCD researchers have developed the WEN Assessment methodology to facilitate the process to study the WEN relationship, establish WEi metrics, identify REMs and provide a decision-making roadmap tool[3].
The WEi metric is a standard unit of value used to compare results before and after the implementation of energy and water conservation projects. The WEi metrics are established under operational conditions providing real time measures to validate results (M&V).
UCD Researchers identify targeted WEN unit operations (WEN Points), collect archival data and conduct field measurements to obtain all the data that is required to calculate the WEi value, by WEN Point. The WEN Tool offers a roadmap approach to identify short, medium and long term resource efficiency measures (REMs). The WEN Tool models potential greenhouse gas (GHG) emission reductions from energy conservation projects and enhanced bioenergy generation.
a.Whole Systems Approach
A Whole Systems Approach is used to analyze the results from the WEN Assessments (Steam, Pump, Fans and Wastewater) to offer an inclusive understanding of the industrial and municipal WEN systems. The analysis of these results and the establishment of WEi base line metrics are essential to identify water conservation opportunities and energy resource efficiency measures. UCD Researchers will tailor the WEN Tool to meet the characteristics and objectives of the RWCF and the Campbell Soup Company, accordingly.
2. Activities, Deliverables, Time Lines
The UCD proposal work plan provides a scope of work and separate work plans for the RWCF and the Campbell Soup projects. The RWCF project work plan will include tasks to conduct a Pump WEN Assessment and a Biomethane Potential Assessment. The Campbell Soup project work plan will also include a WEN Assessment tasks to conduct Steam, Pump, Fan ESAs. The WEN Assessment results are utilized to calculate the technical characteristics of the hot tomato water conservation project. These results are used to conduct a Cost Benefit Analysis and issue an economic potential final report. The Campbell Soup project work plan will also include tasks to conduct a wastewater system assessment and a solid organic residue assessment.
Upon the completion of these previous tasks, the work plan calls for the development of a mathematical model to establish the WEN relationship at the Campbell Soup Stockton facility. The model will be used to simulate the technical characteristics and potential economic results from the installation of the water conservation project. At this point the Campbell Soup Company will have the opportunity to evaluate the results achieved and decide to invest in the hot tomato water conservation project. If the Campbell Soup Company decides to move forward with the project, UCD will sign a service agreement to assign responsibilities to design and install the water conservation project.
The RWCF and Campbell Soup work plans will provide descriptions of the work to be performed, the deliverables and the time of completion in each task. The UCD Proposal Work Plan will be completed using the Appendix C format.
System Map
Implementing Organization and Secondary Implementing Organizations
UCD Researchers are collaborating with the City of Stockton, Regional Wastewater Control Facility (RWCF) and the Campbell Soup Company to achieve water and energy savings. The UCD submits the grant proposal to fund the structural and non-structural solution projects at RWCF and Campbell Stockton. The RWCF and Campbell staff will provide support to UCD Researchers conducting WEN Assessments. The Campbell Soup Company will receive funding through this grant to design and purchase the water conservation infrastructure for the Campbell Stockton facility.
The City of Stockton RWCF is located at 2500 Navy Drive, Stockton, California, 95206. The City of Stockton Municipal Utilities Department treats 32 million gallons of wastewater per day with the RWCF as the tertiary treatment facility before discharging clean water into the San Joaquin River. The City of Stockton MUD also cogenerates 17,600 kilowatts per year[4].
Figure 1. Project System Map Benefit Area
The Campbell Soup Stockton facility is located at 760 Industrial Drive, Stockton, California, 95206. Currently the Campbell Soup facility discharges 133 million gallons of wastewater to the RWCF[5], from a distance of less than six miles. As of 2009, the RWCF collected almost 500 million gallons of wastewater from nine food processing facilities among the more than 33 industrial customers[6].
The water conservation infrastructure will deliver direct benefits to the Stockton area and the Sacramento-San Joaquin Delta Hydrologic Region by avoiding the pumping of over 1.7 billion gallons of groundwater over the life of the project[7]. The water conservation project can also recover over 20 MMBtu of natural gas, from tomato water waste heat recycled to the cold brake unit operation, reducing GHG emissions by 106,040 metric tons of carbon dioxide equivalent[8].
The WEN Tool is transferable to other RWCF industrial customers, in particular, the tomato processing facility formerly owned by Unilever Best Foods, currently operated by the Mizkan Group[9], discharging almost 155 million gallons of wastewater in 2009[10].
Scope of Work
UCD Researchers are responsible to manage the implementation of the proposed projects at the RWCF and at the Campbell Soup facility. This work plan includes a Scope of Work section for RWCF WEN Assessment Project and a Scope of Work section for the Campbell WEN Assessment Project.
Scope of Work for the City of Stockton RWCF WEN Assessment Project
UCD Researchers will develop a tailored WEN Tool that provides the theoretical and practical foundations to implement the WEN Assessments at the RWCF facility. The WEN Tool is used by UCD researchers and consultants to conduct WEN Assessments, with support from RWCF staff.
UCD Researchers appreciate the support offered by the RWCF and their desire to see the Campbell Soup Company improve the competitiveness of their Stockton facility[11].
Task 1. Develop the Stockton Regional Wastewater Control Facility WEN Tool
UCD Researchers will conduct multiple walkthrough site visits to the RWCF to map the targeted WEN Points. UCD Researchers will design the RWCF WEN Tool to: 1) Conduct a Pump ESA of the pumping systems identified as targeted areas, and 2) Conduct a BioMethane Potential (BMP) Assay Protocol[12]. UCD Researchers will use the ASME Pumping System Industrial Assessment Standard to collect historical and field data, conduct measurements under full operational conditions. The BMP results will be used to estimate biomethane yields and the potential to enhance productivity under state-of-the-art laboratory conditions. The WEN Tool provides the guidelines, the standards, templates and calculators to establish the pumping system’s WEi metric and to conduct the BMP assessment.
Deliverables: Due Dates
Draft WEN Assessment Tool 9/15
Final WEN Assessment Tool12/15
Task 2. Conduct the Pumping System Assessments:
UCD Researchers will conduct Pumping System Assessments (PSAs) at targeted locations within the RWCF. Working with facility managers, UCD Researchers will identify key WEN Points where to conduct PSAs, using the flow diagram shown in Figure 2[13].
UCD Researchers use the WEN Tool to catalog the data that is required to calculate the OPE of pumps engaged in the WEN relationship at WEN Point. The following information is obtained to conduct the PSAs:
- Electricity demand, consumption and cost
- Operating hours
- Pump and motor nameplate ratings
- Operating duty (fraction of time the pump runs at specified condition)
- Flow rate
- Pump total head (calculated from pressure and line dimensional data)
- Electric power current and voltage
- Maintenance information
Figure 2. RWCF Flow Diagram
The WEN Tool is designed to evaluate each pump performance and derive the OPE values, to calculate the WEi by WEN Point. The WEN tool provides information to identify energy efficiency and water conservation opportunities. The improvements will increase pumping plant productivity and reduce total kilowatt hours (kWh) of electricity used per unit of water pumped. The Pump ESA results are used to establish theWEi metrics as the baseline of information to compare before and after results from water conservation and energy efficiency projects.
Figure 1. City of Stockton RWCF Facility
UCD Researchers cannot predict the potential electricity conservation at the RWCF. However, the CEE National Municipal Water and Wastewater Facility Initiative identifies pumping systems as an Energy Conservation Measure with estimated savings of 20 percent[14]. The Pump ESA will identify the pumping systems with technical potential to achieve higher levels of efficiency.
Deliverables:Due Dates
WEN Tool Excel Folder3/16
WEi by WEN Points Report10/16
Progress ReportsQuarterly
Final Report12/16
Task 3. Conduct the Biomethane Potential Assessment
UCD Researchers will conduct the Biomethane Potential Assessmentat the RWCF bioenergy generation facility. The RWCF WEN Tool will provide the technical guidance needed to conduct a BioMethane Assay Protocol (BMP)[15]. UCD Researchers, with support from RWCF staff, will collect samples and conduct tests at UCD laboratory facilities, to calculate the BMP potential assay. UCD researchers will test the potential to enhance biogas yields with microbial fuel cells (MFC) and model the potential to enhance biogas productivity.
The following methods are used to conduct the BMP:
1)Conduct the Total Volatile Solids (VS) analysis by drying solid and liquid residues and comparing sample mass prior to and following combustion.
2)Perform anaerobic digestion of additional solid and liquid residues using a high-throughput, real-time biogas measurement array of batch anaerobic digesters currently in the laboratory of the PI.
3)Monitor total biogas production metrics, including yield and biogas quality (% methane in biogas).
4)Conduct final BMP calculations using the following formula (1)
Formula (1) BMP Calculation[16].
Figure 3 provides a flow diagram for the RWCF bioenergy facility, including the location of the anaerobic digesters (ADs) and the electric power generation and cogeneration systems. The RWCF processes more than 40,000,000 pounds of sludge per day, generating 17,600 kilowatts per year, with bio solids providing additional energy to engine generators. This on-site energy production supplies up to 65 percent the RWCF’s power needs[17].
Figure 3. RWCF Bioenergy Facility Flow Diagram
UCD Researchers estimate that RWCF generates 17,600 kW per year, reducing utility electricity demand by 65 percent. Assuming that total electricity demand is 2.7 megawatts of electricity per year and that there is the potential to increase energy efficiency by 10 percent. RWCF operates 24 hours a day during 365 days per year.
(1)17,600 x 100/65 = 27,077 kilowatts = 2.7 megawatts
(2)27,077 x 24 x 365 = 237,194,520 kWh
Deliverables:Due Dates
BMP Assay Protocol Report2/16
Progress ReportsQuarterly
Final Report6/16
Summary
UCD researchers appreciate that RWCF will participate with the Campbell Soup Company to implement the WEN Assessment Tools. The UCD methods and expertize are available to the public to conduct energy system assessments and establish WEi metrics to help RWCF identify opportunities to improve pumping plant efficiencies. UCD researchers offer unique know-how capabilities and laboratory resources to conduct the BMP assessment, under different practices and technological conditions with the goal to enhance biogas yields.